US 11,919,082 B2
Method for making turbine engine components using metal injection molding
Timothy Paul Fuesting, Indianapolis, IN (US); and Logan Kroneman, Indianapolis, IN (US)
Assigned to Rolls-Royce Corporation, Indianapolis, IN (US)
Filed by Rolls-Royce Corporation, Indianapolis, IN (US)
Filed on Oct. 28, 2021, as Appl. No. 17/513,743.
Prior Publication US 2023/0140657 A1, May 4, 2023
Int. Cl. B22F 3/10 (2006.01); B22F 3/22 (2006.01); B22F 3/24 (2006.01); B22F 5/00 (2006.01); B22F 5/04 (2006.01)
CPC B22F 3/225 (2013.01) [B22F 3/10 (2013.01); B22F 2003/247 (2013.01); B22F 5/009 (2013.01); B22F 5/04 (2013.01); B22F 2998/10 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A method for manufacturing a turbine shroud segment with at least one undercut region, the method comprising:
forming a first removable insert comprising an external surface corresponding to at least a portion of a wall of a first undercut region of the at least one undercut region in the turbine shroud segment, wherein the first removable insert does not extend beyond the first undercut region;
forming a second removable insert comprising an external surface corresponding to at least a portion of a wall of a second undercut region of the at least one undercut region in the turbine shroud segment, wherein the second removable insert does not extend beyond the second undercut region;
placing the first removable insert and the second removable insert in a mold comprising a mold cavity corresponding to a shape of the turbine shroud segment, wherein the first removable insert and the second removable insert are retained in the mold cavity with at least one fastener, and wherein the second undercut region is opposite the first undercut region in the mold cavity;
injecting a metal injection molding (MIM) feedstock into the mold cavity and around the first removable insert and the second removable insert to form a shroud green body with the first undercut region and the second undercut region; and
sintering, while the shroud green body remains in the mold, the shroud green body to form a shroud body of the turbine shroud segment, wherein the first removable insert and the second removable insert in the mold cavity are at least partially dissolved during or after the sintering step.